CESAB BT BLITZ 312, Service Manual

Page 1: ...SERVICE MANUAL C3E120 C4E120 C3E150 C4E150 C3E160 C4E160 C3E160L C4E160L C3E180 C4E180 C3E180L C4E180L C3E200 C4E200 036 0410 07 04 2005...

Page 2: ...PAGINA INTENZIONALMENTE BIANCA INTENTIONALLY LEFT BLANK PAGE INTENTIONNELLEMENT BLANCHE ABSICHTLICH FREIGELASSENE SEITE P GINA INTENCIONALMENTE BLANCA...

Page 3: ...ESAB S p a reserves all rights of reproduction of this handbook The text and the numbering system may not be used in other printed matter reprinted or translated whether entirely or in part without wr...

Page 4: ...MOTORS ENGINES chapter 1000 TRANSMISSION DRIVE GEAR chapter 2000 BRAKE WHEEL chapter 3000 STEERING SYSTEM chapter 4000 ELECTRICAL SYSTEM chapter 5000 HYDRAULIC PNEUMATIC SYSTEM chapter 6000 MAST GROU...

Page 5: ...chapter A page 1 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 CHAPTER A GENERAL INFORMATION...

Page 6: ...chapter A page 2 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 GENERAL INFORMATION INDEX TECHNICAL DATA page3...

Page 7: ...chapter A page 3 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 TECHNICAL DATA...

Page 8: ...chapter A page 4 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07...

Page 9: ...chapter A page 5 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07...

Page 10: ...page 6 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 PAGINA INTENZIONALMENTE BIANCA INTENTIONALLY LEFT BLANK PAGE INTENTIONNELLEMENT BLANCHE ABSICHTLICH FREIGELASSENE SEITE P GINA INTENCIONALMENT...

Page 11: ...chapter 0000 page 1 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 CHAPTER 0000 CHASSIS...

Page 12: ...ric 036 0410 07 CHASSIS INDEX TRUCK S LAY OUT page3 PEDALS page4 DRIVE DIRECTION LEVER ON STEERING COLUMN page4 STEERINGCOLUMNPUSHBUTTONS page5 LOAD HANDLING COMMANDS page6 DASHBOARD page7 DASHBOARD C...

Page 13: ...A Mastframe B Openingforliftingbattery C Seat D Electroniccontrolunitcompartment E Counterweight F Hydraulicvalvecommands G Controlvalvecover H Liftingjack I Liftingforkcarriage J Overhead guard K Pre...

Page 14: ...R ON STEERING COLUMN Alternative version Direction selector lever F 1 Forward direction 0 Neutral 2 Backward direction Parking brake lever A Emergency push button H Single drive pedal G Horn push butt...

Page 15: ...w Settingscanbeselectedpullingthepushbuttonseveraltimes Threeledswillshowtheselectedprogram as indicated at the dashboard description page item 11 P Maximum drive speed Acceleration and braking action...

Page 16: ...OL VALVE VERSION A JOYSTICK VERSION B FINGERTIPS VERSION C Levers unit H Lifting control lever yellow cap K Tilting control lever green cap J Sideshift control lever red cap L Device control lever opt...

Page 17: ...rakefluidlowlevelwarninglight 4 Lifting speed reduction due to flat battery 5 Presentmandevice warninglight 6 Driveleftmotortemperaturewarninglight 7 Driverightmotortemperaturewarninglight 8 Liftingmo...

Page 18: ...ing light The pilot light comes ON when the driver leaves the driving seat without switching OFF the truck under these conditions the traction and the lifting movement are disabled 6 Drive left motor...

Page 19: ...SERIAL N DRAW BAR PULL 1h SERVICE MASS BATTERY MASS MANUFACT YEAR TENSION kW kg N Without Battery kg kg min kg max V CESAB LDT Bevan Way Smethwick Warley West Midla 1ds B66 1BZ A CAPACITY PLATE ATTAC...

Page 20: ...gequipmentsmustbeusedtolifttheforklifttruckwith overhead guard standard N 2 slings A in accordance with DIN B2N UNI 9531 minimumlength9mandcapacityof2800kg LIFTING OF THE FORKLIFT TRUCK WITH CABIN The...

Page 21: ...chapter 1000 page 1 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 CHAPTER 1000 MOTORS ENGINES...

Page 22: ...chapter 1000 page 2 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 MOTORS ENGINES INDEX ELECTRICAL MOTORS CHARACTERISTICS page3 ELECTRICAL MOTORS ARRANGEMENT page5...

Page 23: ...tric 036 0410 07 MANUFACTURER SAUER DANFOSS SCHABM LLER POWER 4 5 KW f 80 Hz POLES NUMBER 4 FREQUENCY 80 Hz NOMINALVOLTAGE 27 V AC POWER FACTOR cos f 0 915 SERVICE S2 60 INSULATION CLASS F R P M 2295...

Page 24: ...E MANUAL Electric 036 0410 07 MANUFACTURER SAUER DANFOSS SCHABM LLER POWER 10 KW POLES NUMBER 4 FREQUENCY 80 Hz NOMINALVOLTAGE 28 V AC POWER FACTOR cos f 0 83 SERVICE S3 26 INSULATION CLASS F R P M 23...

Page 25: ...chapter 1000 page 5 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 ELECTRICAL MOTORS ARRANGEMENT TRACTION MOTORS LIFTING MOTOR...

Page 26: ...00 page 6 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 PAGINA INTENZIONALMENTE BIANCA INTENTIONALLY LEFT BLANK PAGE INTENTIONNELLEMENT BLANCHE ABSICHTLICH FREIGELASSENE SEITE P GINA INTENCIONALME...

Page 27: ...chapter 2000 page 1 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 CHAPTER 2000 TRANSMISSION DRIVE GEAR...

Page 28: ...hapter 2000 page 2 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 TRANSMISSION DRIVE GEAR INDEX REDUCTION GEAR VIEW page 3 REDUCTION GEAR MAINTENANCE page 4 REPLACEMENT OF THE REDUCTION GEAR page 5...

Page 29: ...chapter 2000 page 3 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 REDUCTION GEAR VIEW Reduction ratio of the reduction gear 1 18 2...

Page 30: ...afterrunningthetruckforafewminutes to warm them up For a correct operation of the reduction gears do not fill with more oil than necessary PLUG FOR OIL LEVEL CHECK AND TOPPING UP OIL DRAIN PLUG REDUCT...

Page 31: ...GEAR Liftthetruck Removethewheelfromthereductiongear Removethecablefortheparkingbrakeand thetubefortheoilbrakesystem Putashimundertheelectricmotor Tubefortheoilbrakesystem Cablefortheparkingbrake Remo...

Page 32: ...00 page 6 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 PAGINA INTENZIONALMENTE BIANCA INTENTIONALLY LEFT BLANK PAGE INTENTIONNELLEMENT BLANCHE ABSICHTLICH FREIGELASSENE SEITE P GINA INTENCIONALME...

Page 33: ...chapter 3000 page 1 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 CHAPTER 3000 BRAKES WHEELS...

Page 34: ...t A C SERVICE MANUAL Electric 036 0410 07 BRAKES WHEELS INDEX SERVICE BRAKES page3 PARKING BRAKE page4 BRAKE OPERATING SYSTEM DESCRIPTION page5 BRAKE DISKS page6 REPLACEMENT OF THE WHEEL BRAKE CYLIND...

Page 35: ...RAKE OIL TANK SERVICE BRAKE Oil bath brakes are inside the reduction gear box and use the same oil SERVICE BRAKE SYSTEM DIAGRAM M Reduction gears and braking unit N Parking brake command O Bleedingscr...

Page 36: ...ck the parking brake travel which should correspond to 3 notches If necessary adjust the appropriate screws X check the condition of the stay bolt cables and the anchors The hand parking brake operate...

Page 37: ...surface ofthereductiongear movesthewheelbrakecylinder Thisturnsaroundthefulcrumandpressesagainstthe brakepinthatpushesthepad Thepadpushesthemainpistonthatclosesthebrakedisks obtainingthe brakingeffect...

Page 38: ...thatotherwisewouldturnwiththebrakedisks Thepinionturnsongeargroup2wheregeargroup1 andthebrakedisksarefixed Thebrakediskshaveatootedshapeontheexternal diameterinordertoblockthemonthereductiongear body...

Page 39: ...e cylinder D it is possible to proceed in two different ways 1st WAY 1 Liftthetruck 2 RemovecableEandhoseF 3 RemovewheelA 4 Replacethethreescrewsusedforfixingthe reductiongeartotheelectricmotorwiththr...

Page 40: ...EandhoseF 3 RemovewheelA seepreviouspage 4 Removethescrewsthatfixedthegearboxtothe frame 5 FixbarG of 40cm intotheupmostholeinthe frameusingitasaguidetokeepthereductiongear 5 10cm offtheframe therefor...

Page 41: ...30 mm TIGHTENINGTORQUES STANDARD TYRES 14 daNm 14 daNm 2 3 daNm 13 5 daNm 5 daNm 5 daNm 2 2 daNm 4 9 daNm 0 8 1 2 daNm 20 daNm WHEEL TORQUE steering wheels driving wheels DRIVE UNIT TORQUE electric m...

Page 42: ...0 page 10 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 PAGINA INTENZIONALMENTE BIANCA INTENTIONALLY LEFT BLANK PAGE INTENTIONNELLEMENT BLANCHE ABSICHTLICH FREIGELASSENE SEITE P GINA INTENCIONALME...

Page 43: ...chapter 4000 page 1 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 CHAPTER 4000 STEERING SYSTEM...

Page 44: ...apter 4000 page 2 STEERING SYSTEM INDEX STEERING CONTROL page3 POWER STEERING HYDRAULIC DIAGRAM page4 POWER STEERING HYDRAULIC LAYOUT page5 POWER STEERING SETTING page6 STEERING AXLE 3 WHEELS page8 ST...

Page 45: ...a volume of oil and sends it into the steering cylinder Every 1000 hours checktheentiresystemtoidentifyanyleak anyinterventionmustbecarriedoutwithout pressure in the system Every 5000 working hours r...

Page 46: ...1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 chapter 4000 page 4 FILTER ORBITROL A POWER STEERING HYDRAULIC DIAGRAM STEERING CYLINDER A PUMP TO THE CONTROL VALVES P R I O R I T Y VALVE...

Page 47: ...0 page 5 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 3 AND 4 WHEELS VERSION L R L R 3 WHEELS L 4 WHEELS L R Drain Oilinlet Load sensor and Valve for the maximum pressure ORBITROL LOAD SENSOR R L...

Page 48: ...07 chapter 4000 page 6 The same pressure is used for both versions 3 and 4 wheels Adjusting Screwin highterpressure Screwout lowerpressure POWER STEERING SETTING Inordertosetthepressureremovethecapand...

Page 49: ...lwaysreachestheloadsensoronthepriorityvalve OnthepriorityvalvethereisachannelthatconnectLStoPPinordertoguaranteealwaysaflowofoilforaprompt replayofthesteering Theincreasingofthepressureonthesystemcanc...

Page 50: ...410 07 chapter 4000 page 8 3 WHEEL STEERING AXLE Control of steering unit The steering unit D does not require greasing or lubrication Every 1000 hours check and if necessary adjust the wheel hub bear...

Page 51: ...check and if it is necessary adjust the wheel hub bearings Max steering angle internal wheel B 80 End stroke setting adjustment make the cylinder reach the internal end stroke then operate on the spe...

Page 52: ...ove cap 1 fasten the nut with a torque setting of 6 dNm turn the hub of 2 3 turns in both senses unfasten nut 3 and retighten with a 2 1 daNm torque check that the wheels slide correctly max rolling f...

Page 53: ...chapter 5000 page 1 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 CHAPTER 5000 ELECTRIC ELECTRONIC SYSTEM...

Page 54: ...page13 TRACTIONELECTRICBLOCKDIAGRAM page15 STEERING SYSTEM page16 CONNECTION OF THEAUXILIARY CIRCUIT LIFTING page18 LIFTING ELECTRIC BLOCK DIAGRAM page20 ELECTRICALCIRCUITCONNECTIONTRACTION AND LIFTIN...

Page 55: ...the battery while it is being charged Do not lean metal tools on the battery while under charge Never repair the battery while under charge Check that during the charging phase the electrolyte temper...

Page 56: ...ES NUMBER 4 FREQUENCY 80 Hz NOMINALVOLTAGE 28 V AC POWER FACTOR cos f 0 83 SERVICE S3 26 INSULATION CLASS F R P M 2314 rpm PUMPCAPACITY 11l m LIFTING MOTOR MANIFACTURER SAUER DANFOSS SCHABM LLER POWER...

Page 57: ...e view Encoder Motor signals connector The encoder function is to generate motors feed back signals to thelogicunitis motorrunning R P M rotationdirection Itis built in the bearing placed on the oppos...

Page 58: ...evice with the two longer screws Press on the sensor bearing with the screw Pos 11 Be shure to press only the inner ring of the sensor bearing Put the connection of the temperature sensor in the 9 pin...

Page 59: ...ERATOR PEDAL Set the potentiometer Position the tester set in OHM between the green and the red wire Set the potentiometer from 5 13 to 6 27 KOHM pedal released from 1 087 to 1 32 KOHM pedal pressed A...

Page 60: ...10Amp 2 F2 horn fuse 5 Amp 3 F3 DC DC converter fuse 20Amp 4 Diode LIGHTCARD CONTACTORS 24 VOLT FUSES This box is located under the dashboard and it is used for all the 24 V fuses only 5 Connectorfor...

Page 61: ...73042 360W 2773043 720W 2773044 960W EQUIPMENT CONSUPTION OF THE EQUIPMENT CONNECTED TO 24 V STD MACHINE 86 W REVERCEACUSTIC WARNING 05 W FLASH BEACON 03 W ROTARYBEACON 70 W WIPER 100W 2 WORKING LIGHT...

Page 62: ...z Externaltemperaturerange 30 C 40 C Maximuminvertertemperature atfullpower 75 C ELECTRONIC PANELS TECHNICAL SPECIFICATIONS Inverter for pairs ofAC asynchronous 3 phase motors Regenerativebrakingfunct...

Page 63: ...tfivealarmswithrelativehour meterandtemperaturedisplayedontheconsole Testfunctionwithinconsoleforcheckingmainparameters Hydraulicsteeringfunction 1 tractioninverter thetractioninvertersendsa hydraulic...

Page 64: ...eforecarryingoutanyarc weldingonthetrucks disconnectthebatteryandshort circuittheunitbetween positive andnegative PROTECTIONS ConnectionErrors Allinputsareprotectedagainstconnectionerrors Thermalprote...

Page 65: ...chapter 5000 page 13 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 CONNECTION OF THE AUXILIARY CIRCUIT DUAL AC2 UNIT TRACTION CABLES ASSEMBLY INSTRUCTIONS...

Page 66: ...der power supply C3 KEY Connected to Batt through the series costituited by the key switch the protection diode and a 10A fuse C4 CM Common of FW REV HB PB SEAT ENABLE microswitches C5 SEAT Seatpresen...

Page 67: ...external side Type of PINS used AMP770854 3 ENABLING OF C10 SPEED REDUCTION By connecting a wire between the pin C10 and the positive Vb from the seat switch it is possible to disable the reduction of...

Page 68: ...point B 3 WHEELS 4 WHEELS LEFT RIGHT STEERING POTENTIOMETER 4 WHEELS Whenthepotentiometerreachesthemaximum strokethetractionlogicunitcontrolsthemotor inordertostoponemotorcompletelyaccording to the d...

Page 69: ...hthand 80 2 5Vwithstraightwheel 3 8Vwithmax steeringanglelefthand 58 Black 0 V 3WHEELS Steering potentiometer 3wheels Yellow 12 V Green 0 7Vwithmax steeringanglerighthand 90 2 5Vwithstraightwheel 4 3V...

Page 70: ...chapter 5000 page 18 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 CONNECTION OF THE ELECTRIC CIRCUIT AC2 UNIT LIFTING...

Page 71: ...encoderpowersupply D3 LiftingmotorencoderphaseA D5 LiftingmotorencoderphaseB E4 CM Common of LIFT ENABLE 1st SPEED 2nd SPEED 3rd SPEED 4th SPEED HYDRO SR microswitches E12 HYDRO REQ Inputforhydraulics...

Page 72: ...chapter 5000 page 20 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 LIFTING ELECTRIC BLOCK DIAGRAM CONTROL LOGIC KEY POTENTIOMETER MICROSWITCHES PROGRAMMING CONSOLE KEY...

Page 73: ...chapter 5000 page 21 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 SEGNALI CAN BUS 355 A FUSE 300 A FUSE ELECTRICAL CIRCUIT CONNECTION DUAL AC2 TRACTION UNIT AND AC2 LIFTING UNIT...

Page 74: ...2 ADJUSTBATTERY 3 STEERINGPOTENTIOMETER 4 Vacc PROGRAM 5 STEERTABLE for all references see MAPS FOR USING THE CONSOLE TRACTION in the following pages NECESSARY SETTING AFTER REPLACING THE LIFTING LOG...

Page 75: ...CTION 4 WIRES ANALOGIC CONNECTION SEVERAL WIRES see legend at the next page CAN BUS AND ONBOARD COMMANDS DIAGRAM ARM COMMANDS ARM CARD LIGHT CARD I O CARD DASHBOARD TRACTION ON BOARD COMMAND LIFTING O...

Page 76: ...ward switch horn switch liftingfingertip tiltfingertip fingertip sideshiftfingertip 4 way fingertip opt 5 way fingertip opt ARM CARD LIGHT CARD I O CARD AC2 liftinglogicunit DUAL AC2 tractionlogicunit...

Page 77: ...hipslocatedindifferentpartsofthetruck Oneofthegreatestadvantagesisthatallmicrochipscancommunicatewitheachotherandcontrolfunctionswhich workcontemporaneouslyinashorttime TheCANtransfersalldatagivingpri...

Page 78: ...o inform the card about the potentiometers type used the followingsettingisrequired JOYSTICKS all the dip switches layout pos 9 are setted on OFF position FINGERTIPS the dip switch n 2 layout pos 9 is...

Page 79: ...chapter 5000 page 27 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 FINGERTIP PB1 Horn pushbutton PB2 Backward pushbutton PB3 Forward pushbutton JOYSTICK PB2 PB3 PB1...

Page 80: ...lied to all the other cards FUNCTIONS Controllingofthebacklights The light card permits the automatic control of the back lights according to the operation of the traction motors Thecardiscontrolledby...

Page 81: ...4Volt input for the converter 24 5Volt located on the card Connector 2 It is a connector to 6 Pins PIN 1 CAN L PIN 2 CAN H PIN 3 GND PIN 4 Not used PIN 5 Out put 24Volt PIN 6 Not used Connector 3 It i...

Page 82: ...n motorstemperature sensors Connector J8 J98 BV feedingforMhyriologicunit Connector J10 J40 for the mechanic distributor in this case the voltage on the microis5volt Connector J13 J139 CAN BUS signals...

Page 83: ...the electro control valve group The Mhyrio card receivesthedigitalinputsfromtheCANanditconvertsthem inanalogicsignalstocontrolthesolenoidvalveswith In the front it has three connectors connector 1 is...

Page 84: ...pter 5000 page 32 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 POTENTIOMETER CONFIGURATION ARM COMMAND JOYSTICKS FINGERTIPS VERSION BACKWARD PUSHBUTTON PB2 FORWARD PUSHBUTTON PB3 HORN PUSHBUTTON...

Page 85: ...e amarillo H grigio grey grau gris gris M marrone brown braun marron casta o N nero black schwarz noir negro S rosa pink pink rose rosa R rosso red rot rouge rojo V verde green gr n vert verde Z viola...

Page 86: ...tentiometercanbecarriedoutintwodifferentways Values optained by the console Yellow 1 6 V Green 0 6 1 6 V with pedal pressed Black 0 6 V There is a difference between the values obtained in the two met...

Page 87: ...nedbythemultimeter 137 4 6 V 135 1 1 4 6V withliftingleverpulled 136 1 1 V LIFTING POTENTIOMETER CONFIGURATION CONTROL VALVE VERSION There is a difference between the values obtained in the two method...

Page 88: ...chapter 5000 page 36 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 CONSOLE FUNCTION GENERAL DESCRIPTION...

Page 89: ...tedfromthekeyboard RESTOREPARAMETER ItmakesitpossibletoprogramachopperwiththeparameterscontainedinaprogramgeneratedbyaSAVE ALARMS Theconsolefeaturesthepossibilitytoreadthelastfivealarmmessagesstoredin...

Page 90: ...chapter 5000 page 38 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 MHYRIO UNIT TRACTION UNIT LIFTING UNIT Theconnectionhastobemadewiththemachineatrest CONSOLE CONNECTION...

Page 91: ...otorslowsdown MAX SPEED FORWARD determinesthemaximumspeedinforwarddirection MAXSPEEDBACKWARD determinesthemaximumspeedinbackwarddirection CUTBACKSPEED1 speedreductionwhenthecutbackswitchisactive Turtl...

Page 92: ...chapter 5000 page 40 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 PARAMETER CHANGE DUALAC2 SLAVE TRACTION UNIT NOTAVAILABLE...

Page 93: ...e V E4 inputE13 ifE13isopentheCutbackspeedison istheE13isclosedtheCutbackspeedisoff CUTBACKSPEED2 speedreductionwhenthecutbackswitchisactive V E4 inputE14 ifE14isopentheCutbackspeedisoff ifE14isclosed...

Page 94: ...sideshiftleftsolenoidvalve MIN EVP7 Minvoltageonthe4thwayforwardsolenoidvalve MAX EVP7 Max voltage on the 4th way backward solenoid valve MIN EVP8 Minvoltageonthe5thwayforwardsolenoidvalve MAX EVP8 Ma...

Page 95: ...0 t A C SERVICE MANUAL Electric 036 0410 07 PARAMETER CHANGE DASHBOARD UNIT HOURS COUNTER RUNNING KEY key on lifting unit working hours counter switch DISPLAYON OFF displaiedspeedswitch SPEED RATIO 0...

Page 96: ...the ratio of the two speeds SEATSWITCH stateoftheSeatMicroswitchdigitalinput ON VB active input closed switch OFF GND non active input open switch FORWARD SWITCH state of the Forward direction digital...

Page 97: ...mperaturemeasuredonthealuminumheatsinkholdingtheMOSFET devices SEATSWITCH stateoftheSeatMicroswitchdigitalinput ON VB active input closed switch OFF GND non active input open switch FORWARD SWITCH sta...

Page 98: ...ratorpotentiometer swiper CPOT Thevoltage levelisshownontheLeftHandSideoftheConsoleDisplayandthe valueinpercentageisshownontheRightHandSide LIFTINGSWITCH stateoftheliftingswitch 1STSPEEDSWITCH stateof...

Page 99: ...eringvalve CAN POT GROUP 2 group 2 proportional valves current setpoint received by the canbus 0 100 of the current supplied to the tilt box CAN POT GROUP 3 group 3 proportional valves current setpoin...

Page 100: ...chapter 5000 page 48 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 TESTER MHYRIO UNIT NOTAVAILABLE...

Page 101: ...chapter 5000 page 49 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 TESTER DASHBOARD UNIT NOTAVAILABLE...

Page 102: ...overvoltage protection Logic defect Replace the tractionunit c The alarm appears also when one or more phases of the right traction motor doesn t present a correct insulation Check the motor insulatio...

Page 103: ...current of both inverters is reduced to zero If the alarm is signalled whenthecontrolleriscold Replacethetractionunit 12 MOTOR Thiswarningissignalledifthesensorofthe rightmotor isopened digital TEMPE...

Page 104: ...an that the problemislinkedtotheencoder Anyofthefollowingcomponentsmay haveafault Thelogicinternalcircuit The encoder Thewiring Youmayuseadigitaloranaloguemultemetertodeterminewherethe problem is loca...

Page 105: ...icunithasgeneratedtheproblem 4TheMasterlogicunitreceivestheinformationscamingfromtheSlave logicunitwithatimelagfault The fault can be caused by interference on the can bus Check the CAN BUS comunicati...

Page 106: ...defined by the Set steer min and the Set steer max parameters In the first case repeat the steering potentiometer acquisition In the second case check the steering potentiometer and its wiring again I...

Page 107: ...vervoltage protection Logic defect Replace the tractionunit c The alarm appears also when one or more phases of the left traction motor doesn t present a correct insulation Check the motor insulation...

Page 108: ...current of both inverters is reduced to zero If the alarm is signalled whenthecontrolleriscold Replacethetractionunit 72 MOTOR Thiswarningissignalledifthesensorofthe rightmotor isopened digital TEMPE...

Page 109: ...an that the problemislinkedtotheencoder Anyofthefollowingcomponentsmay haveafault Thelogicinternalcircuit The encoder Thewiring Youmayuseadigitaloranaloguemultemetertodeterminewherethe problem is loca...

Page 110: ...eratedtheproblem 4TheSlavelogicunitreceivestheinformationscamingfromtheMaster logicunitwithatimelagfault The fault can be caused by interference on the can bus Check the CAN BUS comunication brokenlog...

Page 111: ...isappears remember thatthe parameters previously stored have been deleted and replaced by the default values seeadjustintables 33 LOGIC FAILURE 3 Logicdefect Replacetheliftingunit 34 LOGIC FAILURE 2 F...

Page 112: ...rrent sensor Replacetheliftingunit 40 CAPACITOR When the key is switch ON the inverter tries to charge the capacitor CHARGE through a power resistance and check if the capitor are charged within a tim...

Page 113: ...er connector If the problem persists to replace the encoder sensor CODE ALARM DESCRIPTION 43 ENCODER ERROR Encoderfailure This alarm indicates that the encoder information is not correct or is not pre...

Page 114: ...logicunithasgeneratedtheproblem 4TheLiftinglogicunitreceivestheinformationscamingfromtheSlave logicunitwithatimelagfault The fault can be caused by interference on the can bus Check the CAN BUS comuni...

Page 115: ...cunitwithatimelagfault The fault can be caused by interference on the CAN BUS Check the CAN BUS comunication false contact Check the connections of CAN H and CAN L wires brokenlogic ReplacetheMhyriolo...

Page 116: ...mMhyriounit b4 thedashboarddoesn treceiveinformationfromlightscard Combinations of the above alarms as follows d3 d1 d2 d5 d1 d4 d6 d2 d4 d7 d1 d2 d4 dA d2 d8 dB d1 d2 d8 dC d4 d8 dD d1 d4 d8 dE d2 d4...

Page 117: ...t used C7 Not used C8 Not used I O CARD NOT SHOWN BY THE CONSOLE 81 TRACTION Incorrect start sequence control valve version Check INCORRECTSTART forward backward microswitches and relevant cables park...

Page 118: ...0 90 100 CUTBACKSPEED MAXSPEED 10 20 30 40 50 60 70 80 90 100 FREQUENCYCREEP HZ 0 3 0 6 0 9 1 2 1 5 1 8 2 1 2 4 2 7 3 0 MAXIMUMCURRENT IMAX 47 53 58 64 70 76 82 88 94 100 ACC SMOOTH INV SMOOTH STOPSMO...

Page 119: ...esoftware therealrampcouldchangeaccordingtothemotorparameterssettingand obviously accordingtotheload Adjustablewitha1Hzresolutioninthe0to200Hzrange PROGRAMMEDLEVEL PARAMETER UNIT 0 1 2 3 4 5 6 7 8 9 A...

Page 120: ...0 page 68 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 PAGINA INTENZIONALMENTE BIANCA INTENTIONALLY LEFT BLANK PAGE INTENTIONNELLEMENT BLANCHE ABSICHTLICH FREIGELASSENE SEITE P GINA INTENCIONALME...

Page 121: ...chapter 5000 page 69 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 MAPS FOR USING THE CONSOLE TRACTION...

Page 122: ...ectric 036 0410 07 NECESSARYSETTINGAFTER REPLACINGTHETRACTION LOGIC UNIT 1 TRACTIONACQUISITION seefollowingpages 2 ADJUSTBATTERY seefollowingpages 3 STEERINGPOTENTIOMETER seefollowingpages 4 Vacc PROG...

Page 123: ...n the map here below Press ENTER Press ROLLand PARAM together Incasetheconsoleisconnectedtotheliftinglogicunit Itistheconnectionnumberoftheliftinglogicunit Press SET and select the connection number o...

Page 124: ...T BATTERY TYPE 48 72 80 96 ADJUST BATTERY V MAX STEER RIGHT V MAX STEER LEFT V SET STEER 0 POS 2 5V SET STEER RIGHT V SET STEER LEFT V THROTTLE 0 ZONE THROTTLE X ZONE THROTTLE Y ZONE ADJUSTMENT 02 1 9...

Page 125: ...RENT RMS A TEMPERATURE C SEAT SWITCH ON OFF FORW SWITCH ON OFF BACK SWITCH ON OFF ENABLE SWITCH ON OFF VOLTAGE BOOSTER BATTERY VOLTAGE V SET BATTERY TYPE 48 72 80 96 ADJUST BATTERY V AUX OUTPUT VOLT V...

Page 126: ...ompletely BRAKECUTBACK determinesthedecelerationrampwhenthespeedreductioninput becomes activeandthemotorslowsdown MAX SPEED FORWARD determinesthemaximumspeedinforwarddirection MAXSPEEDBACKWARD determi...

Page 127: ...ing ROLL Press OUT to escape Press ENTER Press ROLL MOTOR VOLTAGE FREQUENCY ENCODER SLIPVALUE CURRENT RMS TEMPERATURE TEMPERATURE 1 TEMPERATURE 2 ACCELERATOR STEERANGLE BRAKE PEDAL POTI INTERNALWHEELC...

Page 128: ...2M2B C Program version stored MAIN MENU PARAM CHANGE MAIN MENU TESTER MAIN MENU SAVEPARAM Press ROLL Press ROLL Press ENTER Press ENTER Press ENTER Press ENTER MAIN MENU SAVEPARAM Press OUT to escape...

Page 129: ...2B C Program version stored Press ROLL to select the box 0 31 where you want to save the program Press ROLL Press ROLL MAIN MENU RESTOREPARAM Press OUT to escape Press ENTER toconfirm STORING RUN ALL...

Page 130: ...ARM Press ENTER MAIN MENU ALARM NONE 00000h 00 0 C Press ENTER hourmeter no alarms temperature max 5 alarms stored no alarms stored Press OUT Press ENTER ALARM CODE 23h 2 25 C CLEARLOGBOOK YES ENTERNO...

Page 131: ...reaching the programVACC These are the old parameters stored Press ENTER Reset of the parameters Select the forward direction Presstheacceleratorpedalslowlyuntilthemaximumstroke Press OUT keeping the...

Page 132: ...corresponds to the min voltage 2 Select MAX STEER LEFT pressing ENTER to delete the old parameter with the wheels turned completelyleftandstoretheparameterpressing OUTandthenENTERtoconfirm Thisvalue...

Page 133: ...IG MENU SETOPTIONS DA2M2B C CE1 13 48V 280A 00000 HOUR COUNTER RUNNING KEY ON BATTERYCHECK ON OFF HYDRO KEY ON ON OFF STOP ON RAMP ON OFF AUX INPUT 1 EXCLUSIVEHYDRO OPTION 1 CUT BACK SPEED PEDALBRAKIN...

Page 134: ...PEDAL BRAKING ANALOG DIGITAL SETTEMPERATURE ANALOG DIGITAL NONE STEERTABLE OPTION 1 OPTION 2 Select STOPON RAMPand change the status using PARAM or SET ON ACTIV ATED OFF DEACTIV ATED and store the par...

Page 135: ...k with this configuration SLIP CONTROL MASTER connection number 3 Select SLIP CONTROL ON or OFF and store the parameter pressing OUT and then ENTER to confirm After that switch the truck OFF and ON CO...

Page 136: ...the truck on In order to have a pricise measure of the battery voltage you have to set the parameterADJUSTBATTERY with the same value read directly on the battery by a multimeter Note that the logic...

Page 137: ...of the full charge With highter value there is not the rearm of the indicator It means that it does not come back to 100 The battery indicator is adjustable by the console in order to change the ther...

Page 138: ...URE ANALOG DIGITAL NONE STEERTABLE OPTION 1 OPTION 2 Press ENTER Press OUT Press ENTER Press ROLL Press ENTER SET POT BRK MIN V SET POT BRK MAX V SETBATTERYTYPE 48 ADJUSTBATTERY V MAXSTEERRIGHT V MAXS...

Page 139: ...ENT 02 adjustment of the lowest value of charge of the battery ADJUSTMENT 01 adjustment of the reset value of the battery indicator ADJUSTMENT 01 ADJUSTMENT 02 0 45 70 1 45 98 2 46 22 3 46 51 4 46 75...

Page 140: ...re the following functions SUBMENU SET OPTIONS Not available SUBMENU ADJUSTMENT 1 SET BATTERY TYPE selects the battery nominal voltage 2 ADJUST BATTERY fine adjustment of the battery voltage measured...

Page 141: ...Press ENTER Press ENTER Press ROLL Scroll the parameters using ROLL Press OUT to escape MAIN MENU PARAM CHANGE MAIN MENU TESTER MOTOR VOLTAGE FREQUENCY ENCODER SLIPVALUE CURRENT RMS TEMPERATURE SEAT...

Page 142: ...where you want to save the program SELECT Mod 00 Program number FREE DA2S2B C Program version stored MAIN MENU SAVEPARAM Press ENTER SELECTMod00 FREE Press ENTER READING RUN ALL PARAMETERS MAIN MENU...

Page 143: ...UN ALL PARAMETERS MAIN MENU RESTOREPARAM Press ENTER Press ROLL Press ENTER SELECT Mod 00 Program number FREE DA2S2B C Program version stored Press ROLL to select the box 0 31 where you want to save t...

Page 144: ...RM Press ENTER MAIN MENU ALARM NONE 00000h 00 0 C Press ENTER hourmeter no alarms temperature max 5 alarms stored no alarms stored Press OUT Press ENTER ALARM CODE 23h 2 25 C AREYOUSURE YES ENTER NO O...

Page 145: ...chapter 5000 page 93 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 MAIN MENU PROGRAM VACC SLAVE connection number 4 It must be carried out in the MASTER traction logic unit...

Page 146: ...3 Connect the console to the TRACTIONlogic unit Press ROLLand PARAM together Press ENTER 0withdoublepedalversion 1withhandinversorversion 2withinversoronthearm Press OUT Press ENTER to confirm Press R...

Page 147: ...chapter 5000 page 95 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 MAPS FOR USING THE CONSOLE LIFTING...

Page 148: ...0 page 96 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 NECESSARYSETTINGAFTER REPLACINGTHE LIFTINGLOGIC UNIT 1 LIFTINGACQUSITION seefollowingpages 2 VaccPROGRAM withmechanicdistributoronly seefoll...

Page 149: ...ase the console is connected to the traction logic unit Itistheconnectionnumberofthetractionlogicunit CONNECTION NUMBERS 3 TRACTION MASTER 4 TRACTION SLAVE 5 PUMP 9 MHYRIO 11 DASHBOARD Press ROLLand P...

Page 150: ...HzCUTBACK SPEED CUTBACK SPEED 2 1ST SPEED FINE Hz 2ND SPEED FINE Hz 3RD SPEED FINE Hz 4TH SPEED FINE Hz AUX FUNCTION 1 HYD SPEED FINE Hz MAXIMUM CURRENT A AUXILIARY TIME sec MOTOR VOLTAGE FREQUENCY Hz...

Page 151: ...losed CUTBACKSPEED speedreductionwhenthecutbackswitchisactive V E4 inputE13 ifE13isopentheCutbackspeedison istheE13isclosedtheCutbackspeedisoff CUTBACKSPEED2 speedreductionwhenthecutbackswitchisactive...

Page 152: ...ENTER Press ROLL MAIN MENU PARAM CHANGE MAIN MENU TESTER AC2P2BD CE 1 06 48V 350A 00000 MOTORVOLTAGE FREQUENCY ENCODER SLIPVALUE CURRENT RMS TEMPERATURE MOTORTEMPERATURE SEATSWITCH ACCELERATOR LIFTIN...

Page 153: ...P2B D Program version stored Press ROLL Press ROLL Press ENTER Press ENTER Press ENTER Press ENTER Press OUT to escape Press ENTER toconfirm MAIN MENU PARAM CHANGE MAIN MENU TESTER MAIN MENU SAVEPARAM...

Page 154: ...B D Program version stored Press ROLL to select the box 0 31 where you want to save the program MAIN MENU RESTOREPARAM Press OUT to escape Press ENTER toconfirm STORING RUN ALL PARAMETERS MAIN MENU RE...

Page 155: ...TER hourmeter no alarms temperature max 5 alarms stored no alarms stored Press OUT Press ENTER AREYOUSURE YES ENTER NO OUT LOGBOOKCLEARED PRESS OUT Press OUT to escape Press ENTER toconfirm Press OUT...

Page 156: ...the programVACC These are the old parameters stored Press ENTER Reset of the parameters Pulltheliftingleverslowlyuntilthemaximunstroke Press OUT keeping the lever pulled Press ENTER to confirm and rel...

Page 157: ...t work with this configuration SLIP CONTROL PUMP connection number 5 Select SLIP CONTROL ON or OFF and store the parameter pressing OUT and then ENTER to confirm After that switch the truck OFF and ON...

Page 158: ...N 1 CUT BACK SPEED PEDAL BRAKING ANALOG DIGITAL SETTEMPERATURE ANALOG DIGITAL NONE STEERTABLE OPTION 1 OPTION 2 Press ENTER Press OUT Press ENTER Press ROLL Press ENTER SET BATTERYTYPE 48 ADJUST BATTE...

Page 159: ...ENTER Press ROLL withelectricdistributor withmechanicdistributor Connect the console to theLIFTINGlogic unit Press OUT Press ENTER to confirm LIFTING ACQUISITION Lifting connection number 5 CONFIG MEN...

Page 160: ...0 page 108 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 PAGINA INTENZIONALMENTE BIANCA INTENTIONALLY LEFT BLANK PAGE INTENTIONNELLEMENT BLANCHE ABSICHTLICH FREIGELASSENE SEITE P GINA INTENCIONALM...

Page 161: ...chapter 5000 page 109 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 MAPS FOR USING THE CONSOLE MHIRIO...

Page 162: ...0 page 110 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 PAGINA INTENZIONALMENTE BIANCA INTENTIONALLY LEFT BLANK PAGE INTENTIONNELLEMENT BLANCHE ABSICHTLICH FREIGELASSENE SEITE P GINA INTENCIONALM...

Page 163: ...CRIPTION OF THE CONSOLE STANDARD MENU OF THE MHYRIO UNIT Press ROLLand PARAM together Press SET and select the connection number of the Mhyrio logic unit Press ENTER Press ROLL OUT and SET together Co...

Page 164: ...al EVP2 TYPE Analogic digital EVP3 TYPE Analogic digital EVP4 TYPE Analogic digital EVP5 TYPE Analogic digital EVP6 TYPE Analogic digital EVP7 TYPE Analogic digital EVP8 TYPE Analogic digital PROGRAM...

Page 165: ...ftsolenoidvalve MAX EVP6 Maxvoltageonthesideshiftleftsolenoidvalve MIN EVP7 Minvoltageonthe4thwayforwardsolenoidvalve MAX EVP7 Max voltage on the 4th way backward solenoid valve MIN EVP8 Minvoltageont...

Page 166: ...ber 9 Press ENTER Press ROLL BATTERYVOLTAGE V VALVESSUPPLY V CAN POT EVP CAN POT GROUP 1 CAN POT GROUP 2 CAN POT GROUP 3 CAN POT GROUP 4 INPUT 0 ON OFF INPUT 1 ON OFF INPUT 2 ON OFF ANALOG INPUT 1 0 2...

Page 167: ...EE MHYCB Program version stored Press ENTER SELECTMod00 FREE Press ENTER READING RUN ALL PARAMETERS MAIN MENU SAVEPARAM Press ENTER Press OUT to escape Press ENTER toconfirm READING RUN ALL PARAMETERS...

Page 168: ...s ROLL to Select the box 0 31 where you want to save the program Press ROLL Press ENTER Press ENTER Press ROLL Press ROLL MAIN MENU RESTOREPARAM MAIN MENU RESTOREPARAM STORING RUN ALL PARAMETERS Press...

Page 169: ...ALARM Press ENTER MAIN MENU ALARM NONE 00000h 00 0 C Press ENTER hourmeter no alarms temperature max 5 alarms stored no alarms stored Press OUT Press ENTER ALARM CODE 23h 2 25 C CLEARLOGBOOK YES ENTER...

Page 170: ...chapter 5000 page 118 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 MAIN MENU PROGRAM VACC Mhyrio connection number 9 Not available...

Page 171: ...chapter 5000 page 119 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 MAPS FOR USING THE CONSOLE DASHBOARD...

Page 172: ...0 page 120 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 PAGINA INTENZIONALMENTE BIANCA INTENTIONALLY LEFT BLANK PAGE INTENTIONNELLEMENT BLANCHE ABSICHTLICH FREIGELASSENE SEITE P GINA INTENCIONALM...

Page 173: ...ted to the traction logic unit Itistheconnectionnumberofthetractionlogicunit CONNECTION NUMBERS 3 TRACTION MASTER 4 TRACTION SLAVE 5 PUMP 9 MHYRIO 11 DASHBOARD Press ROLLand PARAM together Press ENTER...

Page 174: ...e parameter HOURS COUNTER is switched in KEY ON option the hourglass will start to blink whenever the ignition key will be tourned on key workhours count If the parameter DISPLAYSPEED is switched ON o...

Page 175: ...chapter 5000 page 123 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 WIRING DIAGRAMS...

Page 176: ...chapter 5000 page 124 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07...

Page 177: ...chapter 5000 page 125 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07...

Page 178: ...chapter 5000 page 126 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07...

Page 179: ...chapter 5000 page 127 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07...

Page 180: ...chapter 5000 page 128 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07...

Page 181: ...chapter 5000 page 129 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07...

Page 182: ...chapter 5000 page 130 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07...

Page 183: ...chapter 5000 page 131 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07...

Page 184: ...chapter 5000 page 132 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07...

Page 185: ...chapter 6000 page 1 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 CHAPTER 6000 HYDRAULIC PNEUMATIC SYSTEM...

Page 186: ...Electric 036 0410 07 HYDRAULIC PNEUMATIC SYSTEM INDEX CONTROL VALVE SYSTEM CONTROL VALVE VERSION page3 CONTROL VALVE SYSTEM JOYSTICKS FINGERTIPS VERSION page9 POWER STEERING HYDRAULIC DIAGRAM page13 O...

Page 187: ...chapter 6000 page 3 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 HYDRAULIC DIAGRAM Control valve version ORBITROL LIFTING STEERIG AXLE TILTING SIDESHIFT...

Page 188: ...5 Bar CONTROL VALVE HYDRAULIC SYSTEM Control valve version 3 AND 4 WHEELS Manometerconnection Loweringvalve Priorityvalve Drainhose Hydraulicoiltank AGIP ARNICA 46 20litres Thecorrectpositionofthevalv...

Page 189: ...POINT FOR HYDRAULIC PRESSURE CONTROL screw in to increase pressure screw out to decrease pressure HYDRAULIC CONTROL VALVES Control valve version Sideshift max pressure valve Lifting max pressure valv...

Page 190: ...age 6 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 CONTROL VALVE 4th way Lifting Sideshift Tilting Sideshift max pressure valve Tilting max pressure valve 4th way max pressure valve Lifting max p...

Page 191: ...It corresponds to the maximum load of the machine at maximum load FFL Full free loft mast TV Total visibility mast m sec Lifting speed min 0 30 m sec it means 3 3 sec to cover 1 meter max 0 50 m sec i...

Page 192: ...ORMANCE Here below the table with the performance of a STD machine Q1 It corresponds to the maximum load of the machine at 3mt See capacity plate Exercise It means mast in movement End stroke It corre...

Page 193: ...chapter 6000 page 9 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 HYDRAULIC DIAGRAM Joysticks fingertips version LIFTING STEERIG AXLE TILTING SIDESHIFT ORBITROL 4th WAY...

Page 194: ...AL Electric 036 0410 07 ELECTRIC CONTROL VALVE HYDRAULIC SYSTEM Joysticks fingertips version 3 AND 4 WHEELS Manometerconnection Loweringvalve Priorityvalve Drainhose Hydraulicoiltank AGIP ARNICA 46 20...

Page 195: ...caseoffailure oftheliftingsolenoidvalve 2 Maximumpressurevalve 3 Liftingbox 4 Tiltbox 5 Sideshiftbox 6 4 Way box 7 Proportionalvalve EVP 8 Drainpipeconnection 9 Mainliftingpipeconnection HYDRAULIC ELE...

Page 196: ...on lifting sideshift Forsafetyreasonthelogicunitissettothelower speed 4thWAY has two valves already set to 150 Bar Shims are used in order to increase or decrease the pressure Each shim corresponds to...

Page 197: ...chapter 6000 page 13 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 ORBITROL A POWER STEERING HYDRAULIC DIAGRAM STEERING CYLINDER FILTER PUMP TO THE CONTROL VALVES PRIORITY VALVE...

Page 198: ...nge the oil place and stop the truck on a flat surface with the mast tilted backwards and the forks lowered After the first 50 hours filterchange Every 500 hours check the oil level in the tank using...

Page 199: ...can be followedtoreplacethehydraulicoil 1 Todrainthetankitispossibletouseapumptosuch upthehydraulicoil 2 Itisalsopossibletoremovethedrainhoseofthe controlvalvefromthetankandplaceitonan externalcase By...

Page 200: ...CASTROLOPTIMOLT WHITE paste orspray Ifnot restorethelayerwiththeproductbefore mentioned screwinandtightthetwobolts Afterthepumpreplacementitissuggestedtofill thesuctionhoseC seepreviouspage Itisalso p...

Page 201: ...chapter 7000 page 1 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 CHAPTER 7000 MAST GROUP...

Page 202: ...BRAKING EFFECT page 6 SIDE DISPLACEMENT CYLINDER WITH BRAKING EFFECT page 7 SIDE TELESCOPIC CYLINDER WITH BRAKING EFFECT page 8 TELESCOPIC CYLINDER WITHOUT BRAKING EFFECT page 9 CYLINDER CHECKING MET...

Page 203: ...temhasbeenhousedinsidetheprofiles The mast group is a roller type with a variable centre distance i e a fixed roller is fitted on the outer mast and a mobileoneontheinnermast insteadofanumberofmobiler...

Page 204: ...chapter 7000 page 4 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 Intermediate section bar TRIPLE MAST SECTION Fork carriage Internal section bar External section bar...

Page 205: ...chapter 7000 page 5 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 LIFTING CYLINDERS ON THE MAST...

Page 206: ...nnels1and2arepluggedbythecap Therefore sincetheoilflowingbetween the two chambers passes only through channel 3 it has a lower capacity The outcomeisaslowing downor Braking effect Thedownwardslidingof...

Page 207: ...vementisallowedbytheoilflow from chamber A to chamber B through holeFandtheguidering Thedownwardslidingoftherodis allowedbytheopeningofthe Oilinlet circuit sothattheoilcanberetrieved intothetankbymean...

Page 208: ...utofchannel2whiletherod ismoving butfreeing allthesame the passageoftheoilbetweenchannel2and chamberA Thedownwardslidingoftherodisallowed bytheopeningofthe Oilinlet circuit so thattheoilcanberetrieved...

Page 209: ...ictionrings 5 Thedustcontrolring 6 preventsanydirtandwater frompenetratingthecylinder Slight leakages that may occur are directed to the tank through the drain pipe connected to the pipe coupling 7 Th...

Page 210: ...drain pipecoupling itmeansthattheloadloweringisonlyduetotheleakages onthedistributor In the presence of leakages it will be necessary to replace the seal Shouldthisbethecase inspectthecylinderliner 2...

Page 211: ...lers E they have to rotate freely and not to be too worn out A Tilting jacks 2 2 greasenipples B Mast connections 1 1 greasenipples adjust the guide shoes grease the mast guide rollers E FORK CARRIAGE...

Page 212: ...he collars C are present and tightly fixed Every 500 hours check that there is a clearance D of 0 5 to 3 mm between the collar and external lifting jack cylinder check that the self locking nuts E are...

Page 213: ...Picture2 4 removethesafetyclipofthechainpinonthecarriage Picture3 5 removethenutstoppingthechainpinwithatoolasshownin Picture4 Afterthatmovethetwochainstotheoppositesidein order to have more space 6 r...

Page 214: ...PLACING A B B C D E F G Inordertocarryoutthejobproceedasfollows 1 removeoneofthetwosidebarsBfrom theforkcarriage Picture8 2 takeoutthemobileplateC Picture8 3 replacetheupperandlowerguideshoesD E Pictu...

Page 215: ...SPECTION CHECKING THE CHAINS Every 1000 hours Check the condition of the chains which in any case must not be faulty worn out or damaged To check the links for wear use the appropriate gauge Remove th...

Page 216: ...ning lock Check that the fork positioning lock G is in good working order Legibility of marking If the fork arm marking is not clearly legible it must be renewed by the original fork supplier Fork wea...

Page 217: ...chapter 8000 page 1 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 CHAPTER 8000 ATTACHEMENT...

Page 218: ...00 page 2 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 PAGINA INTENZIONALMENTE BIANCA INTENTIONALLY LEFT BLANK PAGE INTENTIONNELLEMENT BLANCHE ABSICHTLICH FREIGELASSENE SEITE P GINA INTENCIONALME...

Page 219: ...chapter 9000 page 1 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 CHAPTER 9000 OPTIONS...

Page 220: ...00 page 2 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 PAGINA INTENZIONALMENTE BIANCA INTENTIONALLY LEFT BLANK PAGE INTENTIONNELLEMENT BLANCHE ABSICHTLICH FREIGELASSENE SEITE P GINA INTENCIONALME...

Page 221: ...chapter B page 1 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 CHAPTER B MAINTENANCE TABLES...

Page 222: ...page 2 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 MAINTENANCE TABLES INDEX OILAND GREASE SPECIFICATION page3 TYRE TIGHTENING TORQUES page3 RUNNING IN MAINTENANCE TIMES TABLE page4 MAINTENANCE T...

Page 223: ...s DRIVE UNIT TORQUE electric motor securing unit securing to frame service brake delivery pipes screw parking brake cable fixing screw oil filling and draining cap VARIOUS TORQUES mast securing U bolt...

Page 224: ...ess The servicing periods are divided into hours considering an average working day of 8 hours of effective operation If the truck is used on average for less than 8 hours per day refer to the schedul...

Page 225: ...ast carriage and chain rollers tilting jacks supply pipes lifting oil filter lifting system oil mast guides mast and jack fixing lifting jack retaining collars fork carriage position forks mast inclin...

Page 226: ...ation BATTERY specific gravity and charge level ELECTRIC MOTORS external cleaning electric fans motor bearings motor supports CHASSIS AND CONTROLS steering and pipe systems seal hoses from orbitrol to...

Page 227: ...chapter C page 1 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 CHAPTER C SAFETY INFORMATION...

Page 228: ...pter C page 2 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 SAFETY INFORMATION INDEX WORK CLOTHES page3 WORK PLACE page3 LIFTING THE TRUCK page3 ELECTRIC PART page4 WELDING page5 TRUCK WASHING pag...

Page 229: ...fting the truck Beforedoinganyjob itisobligatorytoliftthefrontwheelswithblocks toavoidtheriskofaccident 1 Blockthesteeredwheelswithchocks A 2 Tiltthemastbackandplaceblocks B undertheirbase 3 Tiltthema...

Page 230: ...ifiersorpowersupplies Withthekeyswitchedoff thefiltercapacitorscouldremainchargedforsomeminutes Toensuresafeworking conditions weadvise To wait some seconds with the machine stopped and the key insert...

Page 231: ...eperformableinsidetheworkingareawhereyouare Whentheseoperationsarecarriedoutonatruck inordertoavoidthedangerofexplosion coverandprotect thebatteryandthepartsincontactwithfuelcarefully Makesurethatarou...

Page 232: ...page 6 1 2 2 0 t A C SERVICE MANUAL Electric 036 0410 07 PAGINA INTENZIONALMENTE BIANCA INTENTIONALLY LEFT BLANK PAGE INTENTIONNELLEMENT BLANCHE ABSICHTLICH FREIGELASSENE SEITE P GINA INTENCIONALMENT...

Page 233: ...PAGINA INTENZIONALMENTE BIANCA INTENTIONALLY LEFT BLANK PAGE INTENTIONNELLEMENT BLANCHE ABSICHTLICH FREIGELASSENE SEITE P GINA INTENCIONALMENTE BLANCA...

Page 234: ...CESAB S p A via Persicetana Vecchia 10 40132 Bologna Italy Tel 0039 051 20 54 11 Fax 0039 051 72 80 07 E mail cesab cesab it Cargo Range...